Reactivity and Microstructure of Metakaolin Based Geopolymers: Effect of Fly Ash and Liquid/Solid Contents

3D Off-Lattice Coarse-Grained Monte Carlo Simulations for Nucleation of Alkaline Aluminosilicate Gels

This work presents a 3D off-lattice coarse-grained Monte Carlo (CGMC) approach to simulate the nucleation of alkaline aluminosilicate gels, their nanostructure particle size, and their pore size distribution. In this model, four monomer species are coarse-grained with different particle sizes. The novelty is extending the previous on-lattice approach from White et al. (2012 and 2020) by implementing a full off-lattice numerical implementation to consider tetrahedral geometrical constraints when aggregating the particles into clusters. Aggregation of the dissolved silicate and aluminate monomers was simulated until reaching the equilibrium condition of 16.46% and 17.04% in particle number, respectively. The cluster size formation was analyzed as a function of iteration step evolution. The obtained equilibrated nano-structure was digitized to obtain the pore size distribution and this was compared with the on-lattice CGMC and measurement results from White et al. The observed difference highlighted the importance of the developed off-lattice CGMC approach to better describe the nanostructure of aluminosilicate gels.

Towards optimization of mechanical and microstructural performances of Fe-rich laterite geopolymer binders cured at room temperature by varying the activating solution

In the present study, the performances of the end products prepared using calcined iron-rich laterite at 600 °C (LAT600) with different alkaline solution (AS) to calcined laterite (AS/LAT600) mass ratio (0.45-0.65) were investigated. The effect of AS/LAT600 mass ratio on microstructural and mechanical properties of consolidated geopolymer samples, such as compressive strength, porosity, bulk density, water absorption, mercury intrusion porosimetry (MIP) and scanning electron microscopy (SEM) analysis were determined. Geopolymer made with AS/LAT600 ratio of 0.55 yields the highest compressive strength (54 ± 0.38 MPa) and compact structure. Increasing the AS/LAT600 mass ratio (0.45-0.65) increased the setting time, flowability and decreased the SiO₂/Fe₂O₃ and Al₂O₃/Fe₂O₃ molar ratios and compressive strength leading to a weak structure. Both cumulative volume intrusion and cumulative pore area increased from 0.11 to 0.20 mL g^-1 and 65.20 to 90.93 m² g^-1, respectively. Such enhancement is linked to changes that occur into the geopolymer network when high alkaline activator/laterite is used. Therefore, further increase of AS/LAT600 mass ratio improved the workability, delaying the polycondensation rate of dissolved calcined laterite and not positively affecting the mechanical strength development. Nevertheless, the performance of the end products could be found application in building engineering.

Properties and Applications of Geopolymer Composites: A Review Study of Mechanical and Microstructural Properties

Portland cement (PC) is considered the most energy-intensive building material and contributes to around 10% of global warming. It exacerbates global warming and climate change, which have a harmful environmental impact. Efforts are being made to produce sustainable and green concrete as an alternative to PC concrete. As a result, developing a more sustainable strategy and eco-friendly materials to replace ordinary concrete has become critical. Many studies on geopolymer concrete, which has equal or even superior durability and strength compared to traditional concrete, have been conducted for this purpose by many researchers. Geopolymer concrete (GPC) has been developed as a possible new construction material for replacing conventional concrete, offering a clean technological choice for long-term growth. Over the last few decades, geopolymer concrete has been investigated as a feasible green construction material that can reduce CO₂ emissions because it uses industrial wastes as raw materials. GPC has proven effective for structural applications due to its workability and analogical strength compared to standard cement concrete. This review article discusses the engineering properties and microstructure of GPC and shows its merits in construction applications with some guidelines and suggestions recommended for both the academic community and the industrial sector. This literature review also demonstrates that the mechanical properties of GPC are comparable and even sometimes better than those of PC concrete. Moreover, the microstructure of GPC is significantly different from that of PC concrete microstructure and can be affected by many factors.

The Role of an Industrial Alkaline Wastewater in the Alkali Activation of Biomass Fly Ash

Alkali-activated materials are generally considered a more sustainable alternative to Portland cement binders. This derives not only from the use of solid wastes as precursors, but also from the low temperatures required for their synthesis. However, to increase the environmental advantages of these materials, alternative activators should be explored, as the common route involves the use of commercial activators such as sodium silicate or sodium hydroxide solutions. In this work, the possibility of using an alkaline industrial wastewater, coming from a Portuguese paper and pulp industry, as a partial replacement of the commercial sodium hydroxide solution was studied. The results show that the use of the industrial wastewater decreased the workability of the pastes and their setting times, higher incorporations inducing a stronger reduction. Despite this, the results demonstrate the feasibility of replacing up to 25 vol.% of the sodium hydroxide solution with the industrial wastewater without compromising the mechanical performance of the binder. The compressive strength of this composition reached 22.7 MPa, this being slightly higher than the value seen in the reference (20.0 MPa). The use of a waste-containing activator, as reported here, might be a key driver to foster the wider use of this technology.

Fracture Behavior of Long Fiber Reinforced Geopolymer Composites at Different Operating Temperatures

The aim of this article was to analyze the fracture behavior of geopolymer composites based on fly ash or metakaolin with fine aggregate and river sand, with three types of reinforcement: glass, carbon, and aramid fiber, at three different temperatures, approximately: 3 °C, 20 °C, and 50 °C. The temperatures were selected as a future work temperature for composites designed for additive manufacturing technology. The main research method used was bending strength tests in accordance with European standard EN 12390-5. The results showed that the addition of fibers significantly improved the bending strength of all composites. The best results at room temperature were achieved for the metakaolin-based composites and sand reinforced with 2% wt. aramid fiber—17 MPa. The results at 50 °C showed a significant decrease in the bending strength for almost all compositions, which are unexpected results, taking into account the fact that geopolymers are described as materials dedicated to working at high temperatures. The test at low temperature (ca. 3 °C) showed an increase in the bending strength for almost all compositions. The grounds of this type of behavior have not been clearly stated; however, the likely causes of this are discussed.

Conductive Geopolymers as Low-Cost Electrode Materials for Microbial Fuel Cells

Geopolymer (GP) inorganic binders have a superior acid resistance compared to conventional cement (e.g., Portland cement, PC) binders, have better microbial compatibility, and are suitable for introducing electrically conductive additives to improve electron and ion transfer properties. In this study, GP-graphite (GPG) composites and PC-graphite (PCG) composites with a graphite content of 1-10 vol % were prepared and characterized. The electrical conductivity percolation threshold of the GPG and PCG composites was around 7 and 8 vol %, respectively. GPG and PCG composites with a graphite content of 8 to 10 vol % were selected as anode electrodes for the electrochemical analysis in two-chamber polarized microbial fuel cells (MFCs). Graphite electrodes were used as the positive control reference material. Geobacter sulfurreducens was used as a biofilm-forming and electroactive model organism for MFC experiments. Compared to the conventional graphite anodes, the anode-respiring biofilms resulted in equal current production on GPG composite anodes, whereas the PCG composites showed a very poor performance. The largest mean value of the measured current densities of a GPG composite used as anodes in MFCs was 380.4 μA cm^-2 with a standard deviation of 129.5 μA cm^-2. Overall, the best results were obtained with electrodes having a relatively low Ohmic resistance, that is, GPG composites and graphite. The very first approach employing sustainable GPs as a low-cost electrode binder material in an MFC showed promising results with the potential to greatly reduce the production costs of MFCs, which would also increase the feasibility of MFC large-scale applications.

Effect of Silica Fume on Metakaolin Geopolymers' Sulfuric Acid Resistance

To demonstrate the importance of the Si/Al ratio in terms of geopolymer mix designs for acid resistance, a metakaolin-based geopolymer was modified by replacing the aforementioned precursor with different percentages of silica fume. Durability tests were performed by exposing geopolymers with varying amounts of silica fume (up to 9%) to sulfuric acid solution (pH 1) over a period of 84 days. Geopolymer samples were analyzed by X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR) and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX) before and after 7, 14, 28, 56 and 84 days of exposure. To show the time-dependent change of the elemental composition in the corroded layer after sulfuric acid attack, SEM-EDX elemental mappings were conducted and divided into 100 µm segments to generate element-specific depth profiles. The results show that above a critical silica fume content, the erosion of the sample surface by complete dissolution can be prevented and higher amounts of silica fume lead to a significant densification of large (protective) areas of the corroded layer, which delays the progress of corrosion.

Simple Model for Alkali Leaching from Geopolymers: Effects of Raw Materials and Acetic Acid Concentration on Apparent Diffusion Coefficient

This paper investigates alkali leaching from geopolymers under various concentrations of acetic acid solutions. The effects of the raw metakaolin purity as well as fly ash-based geopolymer mortars and pastes are considered. A new methodology for (acetic) acid attack is proposed, adapting standard approaches, where the concentration of the leached alkali in the exposure solution is measured over time. The applicability of a simple diffusion-based mathematical model to determine the apparent diffusion coefficient (D_app) for geopolymer pastes and mortars was validated. At the end of the paste tests, microstructural alterations of the specimens' cross-sections were analyzed microscopically, revealing occurrence of degradation across the outermost surface parts and, especially under acid attack, the formation of long cracks that connect the surface with the intact inner zone. Drastically different D_app are discussed in terms of the differences in the mix designs, principally resulting in different alkali-binding capacities of the geopolymers, while the acid promoted dissolution and increased porosity. As a result of this interpretation, it was concluded that D_app is governed mainly by the chemistry of the alkali release from the gel, as it overruled the effects of porosity and cracks.

Factors Affecting Alkali Activation of Laterite Acid Leaching Residues

In this experimental study, the alkali activation of acid leaching residues using a mixture of sodium hydroxide (NaOH) and alkaline sodium silicate solution (Na2SiO3) as activators is investigated. The residues were also calcined at 800 and 1000 °C for 2 h or mixed with metakaolin (MK) in order to increase their reactivity. The effect of several parameters, namely the H2O/Na2O and SiO2/Na2O ratios present in the activating solution, the pre–curing time (4–24 h), the curing temperature (40–80 °C), the curing time (24 or 48 h), and the ageing period (7–28 days) on the properties of the produced alkali activated materials (AAMs), including compressive strength, porosity, water absorption, and density, was explored. Analytical techniques, namely X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM), and elemental mapping analysis were used for the identification of the morphology and structure of the final products. The experimental results show that the laterite acid leaching residues cannot be alkali activated in an unaltered state, and the compressive strength of the produced AAMs barely reaches 1.4 MPa, while the mixing of the residues with 10 wt% metakaolin results in noticeably higher compressive strength (41 MPa). Moreover, the calcination of residues at 800 and 1000 °C has practically no beneficial effect on alkali activation. Alkali activated materials produced under the optimum synthesis conditions were subjected to high temperature firing for 2 h and immersed in distilled water or acidic solution (1 mol L−1 HCl) for 7 and 30 days in order to assess their structural integrity under different environmental conditions. This study explores the potential of alkali activation of laterite leaching residues amended with the addition of metakaolin for the production of AAMS that can be used as binders or in several construction applications in order to enable their valorization and also improve the environmental sustainability of the metallurgical sector.

Marble Waste Valorization through Alkali Activation

In the present study, the valorization potential of marble waste in the presence of metakaolin via alkali activation was explored. The activating solution used consisted of NaOH and sodium silicate solutions. The effects of marble waste to metakaolin ratio, particle size of raw materials, curing temperature, and Na2O/SiO2 and H2O/Na2O molar ratios present in the activating solution on the main properties and the morphology of the produced alkali-activated materials (AAMs) was evaluated. The durability and structural integrity of the AAMs after firing at temperatures between 200 and 600 °C, immersion in deionized water and 1 mol/L NaCl solution for different time periods and subjection to freeze–thaw cycles were also investigated. Characterization techniques including Fourier transform infrared spectroscopy, X-ray diffraction, mercury intrusion porosimetry and scanning electron microscopy were used in order to study the structure of the produced AAMs. Τhe highest compressive strength (~36 MPa) was achieved by the AAMs prepared with marble waste to metakaolin mass ratio of 0.3 after curing at 40 °C. The results indicated that the utilization of marble waste in the presence of metakaolin enables the production of AAMs with good physical (porosity, density and water absorption) and mechanical properties, thus contributing to the valorization of this waste type and the reduction of the environmental footprint of the marble industry.

Evaluation of Sulfuric Acid-Induced Degradation of Potassium Silicate Activated Metakaolin Geopolymers by Semi-Quantitative SEM-EDX Analysis

Geopolymers are synthesized by mixing powdery solids, rich in amorphous silicon and aluminum species, with an alkaline solution, which leads to the formation of an inorganic alumosilicate network. Their acid resistance is affected by the composition, the porosity, and pore size distribution of the hardened binder as well as the type and concentration of the acidic solution. In the present study, two geopolymer mixtures with varying liquid-to-solid ratios and Si/Al ratios were exposed to a sulfuric acid solution (pH = 1) and analyzed after different durations of exposure (7, 14, 28, 56, and 70 days) by using a light microscope and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX). SEM-EDX elemental mapping was used to evaluate the degradation from depth profiles of silicon (Si), aluminum (Al), and potassium (K) leaching. The results clearly show the leaching kinetics of potassium and the dealumination of the network. The separate consideration of specific reaction steps in the course of degradation, namely the depth of erosion (DE), the depth of deterioration (DD), and the depth of reaction for certain elements (DR(e)), indicate a combination of chemical and diffusion controlled degradation mechanisms.

XRD and TG-DTA Study of New Alkali Activated Materials Based on Fly Ash with Sand and Glass Powder

In this paper, the effect on thermal behavior and compounds mineralogy of replacing different percentages of fly ash with compact particles was studied. A total of 30% of fly ash was replaced with mass powder glass (PG), 70% with mass natural aggregates (S), and 85% with mass PG and S. According to this study, the obtained fly ash based geopolymer exhibits a 20% mass loss in the 25–300 °C temperature range due to the free or physically bound water removal. However, the mass loss is closely related to the particle percentage. Multiple endothermic peaks exhibit the dihydroxylation of β-FeOOH (goethite) at close to 320 °C, the Ca(OH)₂ (Portlandite) transformation to CaCO₃ (calcite) occurs at close to 490 °C, and Al(OH)₃ decomposition occurs at close to 570 °C. Moreover, above 600 °C, the curves show only very small peaks which may correspond to Ti or Mg hydroxides decomposition. Also, the X-ray diffraction (XRD) pattern confirms the presence of sodalite after fly ash alkaline activation, whose content highly depends on the compact particles percentage. These results highlight the thermal stability of geopolymers in the 25–1000 °C temperature range through the use of thermogravimetric analysis, differential thermal analysis, and XRD.